Metrohm Process Analytics 1

Solution provider for online, inline, and atline process

analysis.
2

From the lab to online process analysis:

The best analytical solution

Process analyzers designed and manufactured by All these analysis techniques can be implemented in
Metrohm Process Analytics are the preferred solution for different process environments. But how to bring these
process monitoring in a wide range of industries. solutions to your process is another question. There are
Whatever your project requirements and budget, four ways to implement analysis techniques in your
Metrohm Process Analytics has the right solution for you. process, and depending on which one you implement,
We offer analytical systems for electrochemistry, ion you get several benefits in return.
chromatography, ion selective measurements,
photometry, spectroscopy, and titration.

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Tailored solutions in industrial plants with
online, inline, atline, and offline analysis

Offline measurements: 3
In this type of process analysis, samples are manually Features:
retrieved and transported to a remote laboratory from Reproducibility
the take-off point of the process and high experienced Cost Savings
Efficiency
chemists are needed to perform the analysis. The proper-
Safety
ties of the sample can vary between sampling and analy-
sis, so direct process control is not possible, especially for
unstable samples.

Atline measurements:
With atline analysis, samples are taken manually from a Features:
Reproducibility
take-off point to a process analyzer in proximity to the
Cost Savings
process. This method is ideal when multiple samples
Efficiency
have to be taken at several sampling points along the
Safety
process and across the production floor over long
distances. However, continuous manpower is needed to
collect samples and the frequency of analysis is not
optimal.

Online measurements:
Automation is the key feature of the two following Features:
analysis measurements. With online analysis, sample Reproducibility
Cost Savings
flow is directed from the process loop to the analyzer
Efficiency
automatically (by the use of a fast-loop system) so very
Safety
limited manpower is needed. This method permits auto-
mated sampling, registration, preconditioning, fast feed-
back of results, and efficient process control.

Inline measurements:
For the most «real-time» analysis, inline analysis is the Features:
perfect choice. With this technique, a sensor, fiber or Reproducibility
probe is used to connect the analyzer directly in the Cost Savings
Efficiency
process stream for continuous analysis. The closer your
Safety
analysis techniques get to be «real-time», the more
benefits you get (e.g. higher safety, efficiency, cost
savings, ...).

The following pages give a direct comparison between offline and atline/online/inline
analysis according to these four key qualities: reproducibility, cost savings,
efficiency, and safety.
 High analysis frequency -
High quality products

4 Manual sampling is one of the main disadvantages of

offline analysis. It is time-consuming and the sample has
to be taken to the nearest laboratory, which implies that
the characteristics of the sample no longer represent Inline/Online
the current process conditions (temperature, moisture
Target
content, and many more). This means that any necessary
process adjustments take place hours or even days after Offline
an out-of-specification reading, and reproducibility
of results are not as efficient as with online and inline Target
analysis

Time

Reduce giveaways by Time-consuming manual sampling and long distances to

€ 2.3 M/month the laboratory are eliminated by utilizing online, inline, or

atline process analyzers. Samples are more representative
by implementing inline analysis in a refinery @100,000
and reproducibility of results is increased as the
barrels per day
measurements are performed exactly the same, every
Petrochemistry time.

Reproducibility
 5

Process improvement with online analyzers -

Safeguard your company’s assets

Unforeseen plant shutdowns involve higher expenses Regular control of process parameters is critical to main-
and chemical analysis performed directly at the most tain product and process specifications and to achieve
critical process points is crucial to reduce the potential for optimal product quality and consistency in any industry.
unforeseen plant shutdowns. By providing data in «real- Deviation of these parameters from target can negatively
time» to the industrial control system (e.g. DCS or PLC), impact on product quality and lead to excessive operat-
downtimes are reduced and costly company assets are ing costs, e.g:
safeguarded.
•  Excess chemical consumption

Many processes are controlled within tightly defined •  Reduced throughput/fluctuations

limits for many basic parameters (such as weight, tem-
•  Lower manpower/rework
perature, and pH) or more unique parameters such as
acid concentration in etching solutions, acid-end groups •  Out of specification products/rejects
in polymerizations, product moisture levels in drying
•  Lower yield
processes, amine loading and amine concentration in
CO2 scrubbers, and many more. •  Higher energy usage

€ 5.5M/year
In savings when inline analysis is implemented on a
spray dryer

Cosmetics

Cost Savings
 Accuracy is key -
Increase company profits

6
In offline analysis, samples are taken much less frequently
than online, inline, or atline measurements, making it  4%
much more likely to overcompensate with chemical In extra revenues with inline analysis in fermentation
treatments when not deemed necessary at all. Therefore, process
increased analysis frequency and accuracy is key for
efficient process adjustment and optimization.
Biofuels
Processes that rely on any analytical measurement will
achieve the required accuracy depending on different
aspects:
•  The analytical instrument employed (Standard Error
of Prediction «SEP»)

•  Error of sampling from the process and sample

ROI < 4 months*
by implementing online analyzer systems for liquor
preparation
quality analysis
•  Frequency of analysis
Pulp&Paper
•  Process variation error

Offline laboratory analysis can negatively impact on

process accuracy by introducing manual sampling error.
Also, offline analysis limits the analysis frequency due to
manual limitations and differences between analysts.

Throughput

Operational
costs

Offline Atline Online Inline

*
Process and analyzer-dependent

Efficiency
Safety benefits of process analyzers -
Avoid incidents with process automation

7
Offline process analysis implies multiple manual steps Introducing inline or online process analyzers reduces the
and occupational hazards when exposed to toxic sampling error and increases the sampling frequency as
chemicals and hazardous areas of operation. All of these well as improving the prediction error for the analysis.
steps will be reduced or totally eliminated by using Improving all these steps leads to significant improvements
online or inline process analyzers, which reduces in process accuracy narrowing the normal operating
incidents, resulting in increased plant safety. window to ensure the process is operating at its highest
efficiency and above all in the safest way.
By limiting the manual handling steps, you eliminate any
risk of exposure to hazardous chemicals. Furthermore,
with automated sampling (online, or inline) you can:

•  Detect dangerous sample composition 80% of accidents

in process environments are due to human errors.
•  Avoid hazardous sampling and laboratory analyses When online or inline sampling is implemented,
the origin of accidents is less likely due to human
•  Analyze in hazardous zone (Ex-proof area)
errors.
•  Monitor spillages

•  Reduce waste water streams

•  Detect of out-of-specification process streams

Safety
Subject to change without prior notice
Layout by Andrea Ferreira, Metrohm Applikon B.V., printed in Switzerland at Metrohm AG, CH-9100 Herisau Switzerland
8.000.5340EN – 2020-04

www.metrohm.com